Burner

Abstract

A gas burner including a burner body having a lower housing, an inlet conduit and a combustion surface element attached to the lower housing. A diffuser/reflector positioned within the body encourages even distribution and mixing of a combustible gas/air mixture. The diffuser/reflector is preferably of a sheet metal construction and includes a plurality of stamped openings with each of these openings having an overhanging guide plate. The combustion surface element includes a plurality of integrally formed rigidizing ribs and is made from a high temperature steel alloy wire cloth. The inlet conduit is secured directly or indirectly to an access door/bulkhead that is used to close off an access opening formed in a water heater wall through which the burner is installed. In one construction, an air scoop shrouds the inlet conduit and at least partially defines a flow path of primary air, substantially isolated from the combustion chamber.

We claim: 
     
       1. A gas burner comprising:
 a) a burner body including:
 i) a lower housing said lower housing having a sidewall; 
 ii) a steel alloy screen element defining a combustion surface attached to said lower housing; 
 iii) a diffuser/reflector positioned below said element; 
 
 b) an inlet conduit communicating with said burner body through which a gas/air mixture is delivered to said burner body in a region located below said diffuser/reflector wherein said inlet conduit extends at least partially into said burner body; and, 
 c) said diffuser/reflector including a plurality of openings, each opening having an overhanging guide plate; 
 d) said diffuser/reflector having a somewhat inverted V-shaped configuration, and said openings are arranged in sets of parallel rows and said diffuser/reflector including a second plurality of openings located in an upper region of said diffuser/reflector which do not include associated guide plates; 
 e) said openings of said parallel rows being oriented to direct said gas/air mixture in a direction generally toward said sidewall, said direction being generally transverse to an axis of said inlet conduit. 
 
     
     
       2. The burner of  claim 1  wherein said diffuser/reflector is a sheet metal stamping, and said guide plates are formed by partially stamping through the sheet metal in order to form outwardly extending elements that define the associated overhanging guide plates and said parallel rows are arranged in first and second sets and direct said gas/air mixture in first and second transverse directions respectively, said first transverse direction being substantially opposite the second transverse direction. 
     
     
       3. The gas burner of  claim 1  wherein said lower housing is generally rectangular in shape and has a transverse dimension that is less than its longitudinal dimension, the transverse dimension being transverse to said axis of said inlet conduit. 
     
     
       4. A gas burner comprising:
 a) a burner body including:
 i) a lower housing; 
 ii) a steel alloy screen defining a combustion surface attached to said lower housing; 
 
 b) an inlet conduit communicating with said burner body through which a gas/air mixture is delivered to said burner body in a region located adjacent an inside surface of said combustion surface defining element wherein said inlet conduit extends at least partially into said burner body; and, 
 c) said combustion surface defining element being radiused and including a plurality of integrally formed rigidizing ribs, said ribs being continuous and extending outwardly from said burner body, whereby resonance in said combustion surface during burner operation is inhibited; 
 d) said combustion surface defining element having said inside surface exposed to uncombusted gas/air mixture, said gas/air mixture being combusted or said combustion surface defining element and outside said burner body region. 
 
     
     
       5. The burner of  claim 4  wherein said lower housing includes integrally formed flanges adapted to receive longitudinal edges of said combustion surface defining element by which said combustion surface element is secured, at least partially, to said lower housing, and said lower housing farther comprises a channel member having upwardly directed sides, said flanges being defined at upper edges of said sides and said lower housing further includes a pair of endcaps secured to opposite ends of said channel member, one of said endcaps including an aperture through which said inlet conduit extends, said endcap being captured between a pair of upset ridges formed on said inlet tube, whereby said inlet tube is secured to said burner body. 
     
     
       6. The gas burner of  claim 4  wherein said rigidizing ribs are oriented in a direction that is substantially transverse to an axis of said inlet conduit. 
     
     
       7. A diffuser/reflector for use in a gas burner of the type that includes a burner body having a sidewall and a steel alloy screen element attached to said burner body that defines a combustion surface and an inlet conduit for delivering a gas/air mixture to a region below said screen element, said diffuser/reflector comprising a structure including a first plurality of openings, each opening of said plurality including a transversely extending overhanging element, said elements being arranged to reflect heat away from said lower housing and to encourage gas/air mixing as said gas/air mixture travels from said lower housing to said combustion surface, said overhanging elements arranged to direct the flow of said gas/air mixture in a transverse direction away from an axis of said inlet conduit, and towards said sidewall of said burner body said structure further including another plurality of openings located in an another region of said structure, said other plurality of openings forming part of an unobstructed flow path for said gas/air mixture to said combustion surface. 
     
     
       8. The diffuser/reflector of  claim 7  wherein said structure is generally arcuate. 
     
     
       9. The diffuser/reflector of  claim 7  wherein said transversely extending overhanging elements are arranged in first and second sets, one of said sets directing the gas/air mixture in a first transverse direction away from said axis of said inlet conduit, the other set of said elements directing said gas/air mixture in a second transverse direction from said axis of said inlet conduit, said first and second transverse directions being substantially opposite each other. 
     
     
       10. The diffuser/reflector of  claim 7  wherein said structure includes a non-apertured section that is positioned in said as burner, such that it is located in a region of said as burner that is remote from an inlet end of said gas burner. 
     
     
       11. The diffuser/reflector of  claim 7  wherein said structure is rectangular in shape when viewed in plan and is intended to fit within a rectangularly-shaped burner housing. 
     
     
       12. The diffuser/reflector of  claim 7  wherein said openings and overhanging elements are arranged, such that they form a stair cased profile. 
     
     
       13. The diffuser/reflector of  claim 7  wherein said structure is inserted V-shaped.